boot TOYOTA RAV4 1996 Service User Guide

and sliding surfaces with Dexron-II. Position snap ring on end of axle shaft, with opening facing
downward.
2. Install axle shaft by lightly tapping axle shaft into transaxle. Ensure axle shaft will move inward and
outward approximately .079-.120" (2.00-3.00 mm), and cannot be pulled from transaxle.
3. To install remaining components, reverse removal procedure. Tighten remaining bolts/nuts to
specification. See TORQUE SPECIFICATIONS
. Fill transaxle with Dexron-II (A/T models), or 75W-
90 gear oil with API GL-3, GL-4 or GL-5 rating (M/T models).
Disassembly (FWD M/T)
1. Remove boot clamps, and slide boots from joints. Paint reference marks on outer race and axle shaft for
reassembly reference. See Fig. 6
.
2. Using a screwdriver, remove snap ring from outer tulip race. Remove outer tulip race from inner joint and
axle shaft. Remove snap ring from end of axle shaft retaining inner joint. Paint reference marks on inner
joint, outer cage and axle shaft for reassembly reference.
3. Remove 6 balls and cage. Using a hammer and brass drift, tap inner joint from axle shaft. Remove inner
snap ring. Remove boots from axle shaft. Using a press, remove dust cover from right-side axle shaft.
Using a press and bearing splitter, remove dust cover from left-side inner joint tulip.
4. Disassemble right-side center axle shaft. Using snap ring pliers or a screwdriver, remove snap ring. Using
a press, remove bearing from axle. Using a screwdriver and hammer, remove outer dust deflector from
axle shaft.
Reassembly
1. Using a press, install NEW dust deflector on outboard end of axle shaft. Install NEW snap ring, then
press center bearing on axle shaft. Press NEW dust cover against bearing. On FWD M/T models,
clearance should be .039" (1.0 mm) between bearing and dust cover. On FWD A/T and AWD models,
clearance should be 3.39-3.43" (86-87 mm) between bearing and dust cover.
2. Using a press, install NEW dust cover on axle shaft. Right-side (transaxle side) dust cover must be
positioned 4.134-4.173" (105.0-106.0 mm) from end of axle shaft. Wrap splines on axle shaft with tape to
prevent damaging boots during installation.
3. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install
inboard joint on axle shaft with small diameter side facing outboard joint. Ensure reference mark on inner
joint and axle shaft are aligned. Install NEW snap ring that retains inner joint on axle shaft.
4. Position outer cage and 6 balls on inner joint, and hold in place with grease. Apply grease supplied with
overhaul kit to inner joint and boot. Install inboard joint tulip (center shaft) on inner joint. Ensure match-
marks are aligned. Install NEW snap ring.
5. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer
joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See
AXLE SHAFT LENGTH SPECIFICATIONS
. See Fig. 7 . Install and tighten boot clamps to a
clearance of .047-.157" (1.2-4.0 mm).
Installation
NOTE: Manufacturer does not recommend overhaul of outer joint assembly.

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1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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1. To install, reverse removal procedure. Before installing axle shafts, install NEW snap ring on end of axle
shaft (except right side). Coat axle shaft seals in transaxle with grease. Coat axle shaft splines and sliding
surfaces with Dexron-II. Position snap ring on end of axle shaft, with opening facing downward.
2. Install axle shaft by lightly tapping axle shaft into transaxle. Ensure axle shaft will move inward and
outward approximately .079-.120" (2.00-3.00 mm), and cannot be pulled from transaxle.
3. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS
. Fill transaxle with 75W-90 gear oil with API GL-3, GL-4 or GL-5
rating.
REAR AXLE SHAFTS
Removal (MR2)
1. Raise and support vehicle. Remove rear wheels. Remove engine undercovers. Drain differential oil into
proper container. Unstake drive shaft lock nut. Apply brakes and remove nut. Remove bolt and brake flex
hose bracket from shock absorber. Loosen 2 lower shock absorber bolts and nuts.
2. Remove mounting bolts/nuts and disconnect strut rod from axle carrier. Remove mounting bolts/nuts
from No. 1 lower suspension arm. Remove nut and No. 2 lower suspension arm. Remove 2 lower shock
absorber bolts and nuts. See Fig. 8
. Using plastic hammer, remove drive shaft from axle hub. DO NOT
damage oil seal, boots or dust seal. NOTE: DO NOT damage oil seal, axle shaft boots or Anti-Lock Brake System (ABS)
speed sensor rotor when removing axle shaft.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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Fig. 8: Exploded View Of Rear Axle Shaft (MR2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
Ensure no play exists in inner and outer joints. Inner joint must slide smoothly inward and outward, and be free
from excessive play in radial direction. Check for torn or damaged boots.
Disassembly
1. Remove boot clamps and slide boots from joints. Paint reference marks on outer race and axle shaft for
NOTE: Manufacturer does not recommend overhaul of outer joint assembly.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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reassembly reference.
2. Remove outer race from inboard tripod joint and axle shaft. Remove snap ring from end of axle shaft that
retains inboard tripod joint. Paint reference marks on tripod joint and axle shaft for reassembly reference.
3. Using a hammer and brass drift, tap inboard tripod joint from axle shaft. DO NOT tap on roller of tripod
joint during removal. Remove boots from axle shaft. Using a screwdriver and hammer, remove dust
deflector from axle shaft.
Reassembly
1. Using a press, install NEW dust deflector on left side axle shaft. Wrap splines on axle shaft with tape to
prevent damaging boots during installation. Using a punch and hammer, install straight pin onto center
bearing case on right side axle shaft. Press center bearing into bearing case. Install center bearing and
bearing case assembly to inboard joint shaft. Right side dust cover must be positioned so there
is .039" (1.0 mm) between dust cover and bearing assembly.
2. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install
inboard tripod joint on axle shaft, with small diameter side facing outboard joint. Ensure reference mark
on inboard joint and axle shaft are aligned. Install NEW snap ring that retains inboard tripod joint on axle
shaft.
3. Apply grease supplied with overhaul kit to inner joint and boot. Install outer joint tulip on inner joint.
Ensure match-marks are aligned.
4. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer
joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See
AXLE SHAFT LENGTH SPECIFICATIONS
. See Fig. 9. Install and tighten boot clamps.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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Fig. 10: Exploded View Of Rear Axle Shaft (AWD)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
Ensure no play exists in inner and outer joints. Inner joint must slide smoothly inward and outward, and be free
from excessive play in radial direction. Check for torn or damaged boots.
Disassembly
1. Remove boot clamps and slide boots from joints. Paint reference marks on outer race and axle shaft for
reassembly reference.
2. Remove outer race from inboard tripod
joint and axle shaft. Remove snap ring from end of axle shaft
NOTE: Manufacturer does not recommend overhaul of outer joint assembly.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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retaining inboard tripod joint. Paint reference marks on tripod joint and axle shaft for reassembly
reference.
3. Using a hammer and brass drift, tap inboard tripod joint from axle shaft. DO NOT tap on roller of tripod
joint during removal. Remove boots from axle shaft. Using a screwdriver and hammer, remove dust
deflector from axle shaft.
Reassembly
1. Using a press, install NEW dust deflector on axle shaft. Wrap splines on axle shaft with tape to prevent
damaging boots during installation.
2. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install
inboard tripod joint on axle shaft, with small diameter side facing outboard joint. Ensure reference mark
on inboard joint and axle shaft are aligned. Install NEW snap ring that retains inboard tripod joint on axle
shaft.
3. Apply grease supplied with overhaul kit to inner joint and boot. Install outer joint tulip on inner joint.
Ensure match-marks are aligned.
4. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer
joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See
AXLE SHAFT LENGTH SPECIFICATIONS
. See Fig. 11 . Install and tighten boot clamps.
Fig. 11: Measuring Axle Shaft Length (Rear)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
After installation, check ABS speed sensor si
gnal and wheel alignment.

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1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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Fig. 9: Exploded View Of Front Brake Caliper Assembly (Tundra 4WD Shown; Tacoma 4WD &
4Runner Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
Remove enough brake fluid from master cylinder so overflow will not occur as piston is seated. Seat pistons
using a hammer handle or equivalent. Slide NEW pads and anti-rattle shims into caliper. Install retaining pins
and anti-rattle spring. Install clip into retaining pin holes. Check reservoir fluid level.
FRONT BRAKE CALIPER
Removal & Installation (All Models)
1. Raise vehicle and remove wheels. Disconnect flexible brake hose from caliper. Plug hose to prevent fluid
spillage. Remove caliper mounting bolts or slide pins as necessary.
2. On models with fixed main pin, pivot caliper up to clear edge of disc. Slide caliper off main pin. On all
other models, remove caliper from knuckle or torque plate. To install, reverse removal procedure. On
units with fixed main pin, install boot end in groove of main pin.
FRONT BRAKE DISC out by fluid pressure.

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
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3. Push piston into bore with "C" clamp or wooden hammer handle. Slide caliper onto torque plate carefully
to avoid dama
ging boot on edge of pad.

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
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REMOVAL & INSTALLATION
DRIVE SHAFT
Removal
1. Place a piece of cloth around center universal joint boot to protect boot from damage. Depress brake
pedal and loosen center universal joint set bolts 1/2 turn. See Fig. 1
.
2. Loosen center support bearing bracket. Place reference mark on drive shaft companion flange and
differential companion flange for reassembly reference. Remove center support bearing and differential
companion flange bolts. Pull drive shaft yoke from transaxle and plug transaxle end. Remove drive shaft.
3. If necessary, separate intermediate shaft from rear drive shaft after placing reference marks on joint and
flan
ge. NOTE: For rear axle shaft servicing procedures, see AWD, FWD & RWD AXLE SHAFTS
- MR2 & RAV4 article in DRIVE AXLES.

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1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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1. Mount drive shaft on wood blocks or other stands. With dial indicator, inspect intermediate shaft and rear
drive shaft runout. If runout exceeds .031" (.78 mm), replace shaft.
2. Position dial indicator at end of drive shaft, with tip against inner edge of "U" joint flange. Check
horizontal and vertical runout. If runout exceeds .004" (.10 mm), replace "U" joint flange.
3. Hold drive shaft and attempt to move spider bearing to check for axial play. If axial play is excessive,
repair or replace spider bearing.
4. Ensure cross groove joint turns smoothly in all directions. Check for damage or grease leakage at boot. If
damage is found, replace rear drive shaft.
5. Remove "U" joint flange by loosening stalked part of nut and then removing nut and washer.
6. Turn center support bearing by hand and ensure bearing rotates smoothly. Check condition of seals. If
bearing or seals show wear or damage, replace them.
7. With screwdriver and hammer, remove intermediate shaft dust cover.
Installation
1. Set center support bearing on intermediate shaft. Install plate washer to intermediate shaft. Align
reference marks on flange and shaft. Place flange on shaft.
2. With flange held in vise, press bearing into position by tightening NEW flange nut and washer to 134 ft.
lbs. (182 N.m). Loosen nut and tighten to 51 ft. lbs. (69 N.m). Stake nut.
3. Install NEW intermediate shaft dust cover by tapping into position evenly.
4. Place piece of protective cloth inside "U" joint cover. Align reference marks on intermediate shaft and
rear drive shaft. Install 3 washers and 6 bolts. Temporarily tighten.
5. Insert yoke into "U" joint. Install center support bearing temporarily. Align reference marks on flanges
and connect rear drive shaft with 4 bolts, washers and nuts. Tighten bolts to specification. See TORQUE
SPECIFICATIONS .
6. Depress and hold brake pedal. With hex wrench, tighten cross-groove cover and rear drive shaft. See
TORQUE SPECIFICATIONS
.
7. With vehicle in unladen condition, adjust dimension between rear side of center universal joint and rear
drive shaft. See Fig. 2
.
8. Adjust dimension between rear side of center bearing housing and rear side of bracket to dimension. See
Fig. 3
. Tighten center support bearing bolts to specification. See TORQUE SPECIFICATIONS .
Ensure centerline of bracket is at ri
ght angles to shaft axial line.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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